Trim Component For A Vehicle Interior

ABSTRACT

A trim component for a vehicle interior includes first and second skin layers, a core layer sandwiched between the first and second skin layers with the core layer having first and second sides, a first thermoplastic adhesive material including a polyamide disposed between the first skin layer and the core layer to adhere the first skin layer to the first side of the core layer, and a second thermoplastic adhesive material including a polyamide disposed between the second skin layer and the core layer to adhere the second skin layer to the second side of the core layer.

CROSS REFERENCE TO RELATED APPLICATIONS

The subject application claims priority to and all the benefits of U.S.patent application Ser. No. 15/611,303 filed on Jun. 1, 2017, whichclaims benefit and priority to U.S. Provisional Application No.62/343,947, filed on Jun. 1, 2016, the contents of which are expresslyincorporated herein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to a trim component for avehicle interior.

BACKGROUND

Load floors are often disposed within a cargo, luggage, or other similararea within a vehicle. The load floor is typically constructed fromlightweight materials, and should be strong enough to support a load.However, many load floors still tend to break or crack when exposed toheavy loads. Accordingly, there remains an opportunity to provide a trimcomponent for a cargo area of a vehicle, such as a load floor, that islightweight and can withstand heavy loads without breaking or cracking.

SUMMARY

An embodiment of a trim component for a vehicle interior comprises afirst skin layer, a second skin layer, a core layer sandwiched betweenthe first and second skin layers with the core layer having first andsecond sides, a first thermoplastic adhesive material including apolyamide disposed between the first skin layer and the core layer toadhere the first skin layer to the first side of the core layer, and asecond thermoplastic adhesive material including a polyamide disposedbetween the second skin layer and the core layer to adhere the secondskin layer to the second side of the core layer.

Another embodiment of a trim component for a vehicle interior comprisesa first skin layer formed from a blend of glass fibers and athermoplastic material, a second skin layer formed from a blend of glassfibers and a thermoplastic material, a core layer sandwiched between thefirst and second skin layers with the core layer having a honeycombstructure with first and second sides, a first thermoplastic adhesivematerial including a polyamide disposed between the first skin layer andthe core layer to adhere the first skin layer to the first side of thecore layer, and a second thermoplastic adhesive material including apolyamide disposed between the second skin layer and the core layer toadhere the second skin layer to the second side of the core layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of the present disclosure will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings. It is to be understood that the drawings are purelyillustrative and are not necessarily drawn to scale.

FIG. 1 is a perspective view of a portion of a vehicle having a vehicleinterior with a trim component disposed within the vehicle interior,according to an embodiment of the present disclosure.

FIG. 2 is a schematic, cross-sectional view of the trim component takenalong lines 2-2 in FIG. 1.

FIG. 3 is a perspective view of the trim component of FIG. 2, with oneof the skin layers peeled back to expose the core layer.

FIG. 4 is a schematic, cross-sectional view of a portion of the trimcomponent with a periphery of the trim component pinched to form a seal.

FIG. 5 is a schematic, cross-sectional view of another embodiment of thetrim component.

DETAILED DESCRIPTION

Referring now to the figures, wherein like numerals indicatecorresponding parts throughout the several views, embodiments of a trimcomponent 100 are shown in the figures and are described in detailbelow. In the illustrated embodiments, the trim component 100 is a loadbearing surface, such as a load floor for a vehicle interior that iscapable of bearing a load without damaging the structure of thecomponent. For example, FIG. 1 illustrates a portion of a vehicle 10having a cargo area 12, and the trim component 100 is disposed withinand forms a load floor for the cargo area 12 of the vehicle 10. Whilethe trim component 100 is used in the cargo area 12 of a suitablevehicle, such as a van, truck, sport utility vehicle, and/or the like,it is to be appreciated that the trim component 100 can be used anywherewithin the vehicle interior. It is further to be understood that thetrim component 100 can be used in any type of vehicle, not limited toautomobiles. For example, the trim component 100 could be used inairplanes, boats, trains, trailers, buses, etc.

An embodiment of the trim component 100 is described below withreference to FIGS. 2-4. The trim component 100 is a sandwich compositeincluding a first skin layer 102, a second skin layer 104, and a corelayer 106 sandwiched between the first 102 and second 104 skin layers.The trim component 100 further includes a first thermoplastic adhesivematerial 108 disposed between the first skin layer 102 and the corelayer 106, and a second thermoplastic adhesive material 110 disposedbetween the second skin layer 104 and the core layer 106.

The first 102 and second 104 skin layers are generally lightweight, thinlayers of material disposed on opposing first 112 and second 114 sidesof the core layer 106. Each of the first 102 and second 104 skin layersis formed from a material chosen from glass, a glass fiber compositematerial, a carbon fiber-reinforced polymer, a thermoplastic polymer, athermoset polymer, and combinations thereof. In one particularembodiment, each of the first 102 and second 104 skin layers are formedfrom a blend of glass fibers and a thermoplastic material, such aspolypropylene. In another particular embodiment, each of the first 102and second 104 skin layers are formed from glass fiber-reinforcedpolypropylene. Non-limiting examples of suitable materials for the first102 and second 104 skin layers include SymaLITE®, a glass-reinforcedthermoplastic composite material available from Quadrant EngineeringPlastic Products, Inc. (Reading, Pa.) and SuperLite®, a thermoformablecomposite of plastic resin and long chopped fibers available from HanwhaAzdel Inc. (Forest, Va.). Typically, the first 102 and second 104 skinlayers are formed from the same material, such as the glassfiber-reinforced polypropylene. Alternatively, the first 102 and second104 skin layers could be formed from different materials or combinationsof different materials.

In an embodiment, the weight of each of the first 102 and second 104skin layers is from about 500 to about 2,000 gsm (grams per squaremeter). In another embodiment, the weight of each of the first 102 andsecond 104 skin layers is from about 500 to 1,200 gsm. It is to beappreciated that the weight of the first 102 and second 104 skin layersis typically based, at least in part, on load specifications of thevehicle 12. To this end, the weight of each of the first 102 and second104 skin layers may be lower for smaller vehicles (such as a small sportutility vehicle) and may be higher for larger vehicles (such as a van).In another embodiment, the weight of the first skin layer 102 may bedifferent from the weight of the second skin layer 104. In an example,the weight of the first skin layer 102 (which would be the top layer ofthe trim component 100) may be 25 to 30% less than the weight of thesecond skin layer 104 (which would be the bottom layer of the trimcomponent 100). In another example, the weight of the first skin layer102 (top layer) may be from 500 to 700 gsm, and the weight of the secondskin layer 104 (bottom layer) may be from 900 to 1,200 gsm.

As previously mentioned, the core layer 106 is sandwiched between thefirst 102 and second 104 skin layers. More particularly, the core layer106 has opposed first 114 and second 116 sides, and the first skin layer102 is disposed on the first side 114 of the core layer 106 and thesecond skin layer 104 is disposed on the second side 116 of the corelayer 106. The core layer 106 is a generally thick layer chosen from asuitable lightweight material having relative low strength such that thecore layer 106 has low density and a high bending stiffness. As bestshown in FIG. 3, the core layer 106 has a honeycomb structure. Forexample, the honeycomb structure may have an array of hollow cellsformed between thin vertical material walls. The cells are typicallycolumnar and hexagonal in configuration, however other configurations ofthe cells are also contemplated. In addition, the honeycomb structure isan unfilled honeycomb structure. Alternatively, the honeycomb structurecould be filled; e.g., the columns of the honeycomb structure could befilled with one or more foams for added strength. In one embodiment, thecore layer 106 has a paper-based honeycomb structure, having a paperweight of from 23 to 29 lbs/ft³ (pounds per cubic feet), a thickness ofabout 1 to 4 mm, and a honeycomb cell diameter of from 6 to 12 mm(millimeters). In a non-limiting example, the core layer 106 is formedfrom an Axxor endless honeycomb core, a paper-based honeycomb structureavailable from Axxor By (The Netherlands). Alternatively, the core layer106 could have a honeycomb structure formed from open-cell-structuredfoams, closed-cell-structured foams, balsa wood, syntactic foams, metal,and/or combinations thereof.

The first thermoplastic adhesive material 108 is disposed between thefirst skin layer 102 and the first side 112 of the core layer 106, andthe second thermoplastic adhesive material 110 is disposed between thesecond skin layer 104 and the second side 114 of the core layer 106. Thefirst thermoplastic adhesive material 108 operates to form suitablystrong adhesive bond between the first skin layer 102 and the core layer106, and the second thermoplastic adhesive material 110 operates to forma suitably strong adhesive bond between the second skin layer 104 andthe core layer 106. In an embodiment, the first 108 and second 110adhesive materials are chosen from a thermoplastic adhesive materialincluding a polyamide. It was found that the thermoplastic adhesiveincluding the polyamide forms a suitably strong adhesive bond betweenthe skin layer 102, 104 formed from a blend of glass fibers andpolypropylene (such as glass fiber-reinforced polypropylene) and thecore layer 106. A non-limiting example of a suitable adhesive materialincludes APT 9B9B, a thermoplastic adhesive material including apolyamide available from Advance Packaging Technologies (Waterford,Mich.).

In an embodiment, the thermoplastic adhesive materials 108, 110 areactivated by applying heat. In an example, the thermoplastic adhesivematerial including the polyamide is activated when heated to atemperature of at least 290° F. (at least 143° C.). When activated, thethermoplastic adhesive material 108 forms an adhesive film between thefirst skin layer 102 and the core layer 106, which forms a suitablesurface-area bond between the first skin layer 102 and the core layer106. Similarly, when activated, the thermoplastic adhesive material 110forms an adhesive film between the second skin layer 104 and the corelayer 106, which forms a suitable surface-area bond between the secondskin layer 104 and the core layer 106. In an embodiment, the film formedby each of the first 108 and second 110 adhesive materials has a weightof from 40 to 110 gsm.

The trim component 100 may be formed utilizing a molding/layeringprocess. This process involves applying the first thermoplastic adhesivematerial 108 to the first side 112 of the core layer 106, and disposinga sheet of the first skin layer 102 over the first thermoplasticadhesive material 108 on the first side 112 of the core layer 106. Theprocess further involves applying the second thermoplastic adhesivematerial 110 to the second side 114 of the core layer 106, and disposinga sheet of the second skin layer 104 over the second thermoplasticadhesive material 110 on the second side 114 of the core layer 106. Theskin layer 102, the first adhesive material 108, the core layer 106, thesecond adhesive layer 110, and the second skin layer 104 are laminatedtogether to form a sandwich composite. The composite is placed in anoven and heated at least to the activation temperature of the adhesivematerials 108, 110. In an embodiment, the oven is heated to anactivation temperature of at least 290° F. When activated, the adhesivematerial 108, 110 operates to form an adhesive surface-area bond betweenthe skin layers 102, 104 and the core layer 106.

After heating, the composite is placed into a molding tool (operated ata lower temperature, such as at or near 60° F.) and the composite ismolded into a desired configuration under pressure. During a compressionstage of the molding process, the skin layers 102, 104 are pressed intothe individual cores of the honeycomb structure of the core layer 106,and the underlying adhesive material 108, 110 causes additional bondingof the skin layers 102, 104 to the core layer 106 within the individualcores of the core layer 106. To this end, it has been found that asuitably strong bond between the skin layers 102, 104 and the core layer106 can be formed with the specific of the materials selected for theskin layers 102, 104, the core layer 106, and the adhesive materials108, 110. It has also been found that a superior bond between the skinlayers 102, 104 and the core layer 106 can be formed during thecompression stage of the molding process when the skin layers 102, 104are pressed into the individual cores of the core layer 106.

In an embodiment, and as shown in FIG. 4, the periphery 116 of the trimcomponent 100 may be pinched to form a seal. Pinching may beaccomplished, for example, during the molding process described above.When pinched, the skin layer 102 (with the adhesive material 108),contacts the other skin layer 104 (with the adhesive 110) and forms aseal along the periphery 116 of the trim component 100. By forming aseal, the skin layers 102, 104 encapsulate the core layer 106 to protectthe core layer 106, for example, from degradation.

In another embodiment, and as shown in FIG. 5, the trim component 100may further include cover layers 118, 120 that may be used fordecorative purposes. The cover layers 118, 120 may be disposed on andadhered to the skin layers 102, 104, respectively, utilizing a suitableadhesive (not illustrated in the drawings), non-limiting examples ofwhich include heat-activated polypropylene adhesives or otherthermoplastic perforated or solid film adhesives.

The embodiments and examples of the trim component 100 described indetail above is desirably lightweight and has a suitable stiffness forresistance to deflection and to satisfy load bearing requirements.Additionally, the trim component is desirably strong due, at least inpart, to the strong and superior bond formed between the skin layers102, 104 and the core layer 106. As mentioned above, the strong andsuperior bond is formed by the specific combination of materials of theskin layers 102, 104 (namely, a glass fiber-reinforced polypropylene), apaper-based honeycomb core layer 106, and the thermoplastic adhesivematerial 108, 110 including a polyamide. The strong and superior bondmay also be formed by the specific combination of materials of the skinlayers 102, 104, the core layer 106, and the adhesive materials 108,110, in combination with compression of the layers 102, 104, 106 duringthe molding process.

The trim component 100 of the present disclosure is further illustratedin the Examples set forth below. It is to be understood that theExamples are provided for illustrative purposes and are not to beconstrued as limiting the scope of the present disclosure.

Examples

Three composite samples were prepared, and each of the samples weretested for bond strength utilizing the ASTM C297-15 test method. Thefirst sample is identified by PA-A, which is a sandwich compositeincluding a paper-based honeycomb core sandwiched between AzdelSuperLite® skin layers utilizing APT 9B9B, which is a thermoplasticadhesive material including a polyamide. The second sample is identifiedby PA-Q, which is a sandwich composite including a paper-based honeycombcore sandwiched between Quadrant SymaLITE® skin layers utilizing the APT9B9B adhesive. The third sample is identified by PP-A, which is asandwich composite including a paper-based honeycomb core sandwichedbetween Azdel SuperLite® skin layers utilizing an adhesive materialincluding polypropylene.

The three samples were tested for bond strength utilizing the ASTMC297-15 test method (2015). In particular, this test method is designedto determine the flatwise tensile strength of the core, thecore-to-facing bond, or the facing of an assembled sandwich panel.Utilizing a testing machine, the test method consists of subjecting thesandwich composite samples to a uniaxial tensile force normal to theplane of the sample. The force is transmitted to the sandwich compositesample through thick loading blocks, which are bonded to the sandwichcomposite facings (or skin layers) or directly to the core.

Three specimens of each sample were tested, and a maximum load (N) wasdetermined for each of the specimens at the point when breakage occurredin the adhesive layer at the skin-core layer interface. The maximum loadfor each of the specimens for each sample tested is set forth in Tables1-3 below.

TABLE 1 Bond Strength Test Results for Sample PA-A Specimen Maximum Load(N) Break Mode 1 1153 Adhesion of Core-Facing Adhesive 2 1142 Adhesionof Core-Facing Adhesive 3 1153 Adhesion of Core-Facing Adhesive Mean1149

TABLE 2 Bond Strength Test Results for Sample PA-Q Specimen Maximum Load(N) Break Mode 1 1114 Adhesion of Core-Facing Adhesive 2 1087 Adhesionof Core-Facing Adhesive 3 1336 Adhesion of Core-Facing Adhesive Mean1179

TABLE 3 Bond Strength Test Results for Sample PP-A Specimen Maximum Load(N) Break Mode 1 90 Adhesion of Core-Facing Adhesive 2 104 Adhesion ofCore-Facing Adhesive 3 60 Adhesion of Core-Facing Adhesive Mean 85

As shown in Tables 1-3 above, the sandwich composite samples utilizingthe thermoplastic adhesive material with a polyamide could withstandmuch higher loads (N) compared to the sandwich composite sampleutilizing the adhesive material including polypropylene. These resultsindicate superior bond strength between the skin layers and the corelayer of the composite samples utilizing the thermoplastic adhesivematerial including the polyamide, compared to the composite sampleutilizing the adhesive material including polypropylene.

The invention has been described in an illustrative manner, and it is beunderstood that the terminology which has been used is intended to be inthe nature of words of description rather than of limitation. It is nowapparent to those skilled in the art that many modifications andvariations of the present invention are possible in light of the aboveteachings. It is, therefore, to be understood that the invention may bepracticed otherwise than as specifically described.

What is claimed is:
 1. A trim component for a vehicle interior, said trim component comprising: a first skin layer; a second skin layer; a core layer sandwiched between said first and second skin layers with said core layer having first and second sides; a first thermoplastic adhesive material including a polyamide disposed between said first skin layer and said core layer to adhere said first skin layer to said first side of said core layer; and a second thermoplastic adhesive material including a polyamide disposed between said second skin layer and said core layer to adhere said second skin layer to said second side of said core layer.
 2. The trim component as set forth in claim 1 wherein said first thermoplastic adhesive material forms a film between said first skin layer and said first side of said core layer and bonds said first skin layer to said core layer, and said second thermoplastic adhesive material forms a film between said second skin layer and said second side of said core layer and bonds said second skin layer to said core layer.
 3. The trim component as set forth in claim 1 wherein said film of each of said first and second thermoplastic adhesive materials has a weight of from about 40 to 110 gsm.
 4. The trim component as set forth in claim 1 wherein each of said first and second skin layers is formed from a material chosen from glass, a glass fiber composite material, a carbon fiber-reinforced polymer, a thermoplastic polymer, and combinations thereof.
 5. The trim component as set forth in claim 1 wherein each of said first and second skin layers is formed from glass fiber-reinforced polypropylene.
 6. The trim component as set forth in claim 1 wherein each of said first and second skin layers has a weight of from 500 to 2,000 gsm.
 7. The trim component as set forth in claim 1 wherein a weight of said first skin layer is less than a weight of said second skin layer.
 8. The trim component as set forth in claim 7 wherein said weight of said first skin layer is from 20 to 30% less than said weight of said second skin layer.
 9. The trim component as set forth in claim 1 wherein said core layer has a honeycomb structure.
 10. The trim component as set forth in claim 1 wherein said core layer has a paper-based honeycomb structure having a paper weight of from 23 to 29 lbs/ft³.
 11. The trim component as set forth in claim 1 wherein said core layer has a honeycomb structure with a honeycomb cell diameter of from 6 to 12 mm.
 12. The trim component as set forth in claim 1 wherein said trim component has a periphery and said trim component is pinched along said periphery so that said first skin layer contacts said second skin layer and encapsulates said core layer.
 13. The trim component as set forth in claim 1 further comprising a first cover layer disposed on said first skin layer and a second cover layer disposed on said second skin layer, with said first and second cover layers forming first and second decorative surfaces of said trim component.
 14. A trim component for a vehicle interior, said trim component comprising: a first skin layer formed from a blend of glass fibers and a thermoplastic material; a second skin layer formed from a blend of glass fibers and a thermoplastic material; a core layer sandwiched between said first and second skin layers with said core layer having a honeycomb structure with first and second sides; a first thermoplastic adhesive material including a polyamide disposed between said first skin layer and said core layer to adhere said first skin layer to said first side of said core layer; and a second thermoplastic adhesive material including a polyamide disposed between said second skin layer and said core layer to adhere said second skin layer to said second side of said core layer.
 15. The trim component as set forth in claim 14 wherein said first thermoplastic adhesive material forms a film between said first skin layer and said first side of said core layer and bonds said first skin layer to said core layer, and said second thermoplastic adhesive material forms a film between said second skin layer and said second side of said core layer and bonds said second skin layer to said core layer.
 16. The trim component as set forth in claim 14 wherein said film of each of said first and second thermoplastic adhesive materials has a weight of from about 40 to 110 gsm.
 17. The trim component as set forth in claim 14 wherein said first skin layer is further defined as being formed from a blend of glass fibers and polypropylene, and said second skin layer is further defined as being formed from a blend of glass fibers and polypropylene.
 18. The trim component as set forth in claim 14 wherein each of said first and second skin layers has a weight of from 500 to 2,000 gsm.
 19. The trim component as set forth in claim 14 wherein a weight of said first skin layer is less than a weight of said second skin layer.
 20. The trim component as set forth in claim 14 wherein said core layer is further defined as having a paper-based honeycomb structure having a paper weight of from 23 to 29 lbs/ft³.
 21. A load bearing trim component for a vehicle interior, said trim component comprising: a first skin layer; a second skin layer; a core layer sandwiched between said first and second skin layers with said core layer having first and second sides; a first thermoplastic adhesive material including a polyamide disposed between said first skin layer and said core layer to adhere said first skin layer to said first side of said core layer; and a second thermoplastic adhesive material including a polyamide disposed between said second skin layer and said core layer to adhere said second skin layer to said second side of said core layer. 